Folding door hardware

ABSTRACT

Hinge and alignment hardware assemblies of molded, cast or drawn materials for hinge mounted doors, shutters and panels, particularly in folding door installations; the same having integral mounting means rendering the use of separate fastening devices, such as mounting screws and the like, extraneous, and comprising radially expandable plug portions insertable into socket openings formed in edge or face surfaces of the doors and panels and including means for positively locking the same in operating position. Guide portions on the assemblies align and position the hardware in conjunction with the mounting plug portions and sockets while interlocking detent projections are provided on cooperating hinge members to retain adjacent panels in coplanar alignment.

United States Patent 1 Smith FOLDING DOOR HARDWARE [76] Inventor: LesterL. Smith, 230 W. Monroe St., Suites 2040, Tucson, Ariz.

[22] Filed: Dec. 6, 1973 [21] Appl. No.: 422,321

[52] US. Cl ..16/159, 160/118, 16/149 [51] Int. Cl E05d 5/02 [58} Fieldof Search 16/149, 159, 147; 85/84, 85/83; 160/118 [56} References CitedUNITED STATES PATENTS 2,735,133 2/1956 Hey et al. l6/l59 3,597,7908/1971 Kellems 161/151 Primary liraminer-Paul R. Gilliam Assirian!limminer-Doris L. Troutman Attorney, Agent, or Firni-Davis, McCaleb &Lucas Mar. 18, 1975 [57] ABSTRACT Hinge and alignment hardwareassemblies of molded, cast or drawn materials for hinge mounted doors,shutters and panels, particularly in folding door installations; thesame having integral mounting means rendering the use of separatefastening devices, such as mounting screws and the like, extraneous, andcomprising radially expandable plug portions insertable into socketopenings formed in edge or face surfaces of the doors and panels andincluding means for positively locking the same in operating position.Guide portions on the assemblies align and position the hardware inconjunction with the mounting plug portions and sockets whileinterlocking detent projections are provided on cooperating hingemembers to retain adjacent panels in coplanar alignment.

13 Claims, 12 Drawing Figures FOLDING noon HARDWARE BACKGROUND OF THEINVENTION The traditional and time honored system of mounting andfastening face and edge installed hinges on doors and panels has beenthrough the use of plurality of fastening screws. This requires bothtime and skill for accurate installation. Present day economic factors,such as high labor costs and the lack of skilled workers, have dictatedthe need for an improved time-saving, high production system forinstalling door hardware with accuracy. This is particularly true infolding panel, shutter and door installations currently enjoying popularacceptance and widespread usage in the building arts.

With specific reference to folding door installations, hinges andalignment hardware must be securely mounted and accurately positioned toinsure proper movement of the panels in operation. Desirably, thehardware is inconspicuously positioned while avoiding excessive gapsbetween adjacent panels when the doors are in their closed condition.Typically in the past, hinges have been either flush mounted on the backfaces of the door panels or edge mounted using butterfly or butt hinges.In both instances plural fastening screw elements are used to fasten thehardware in place. The butt hinge installation is even furthercompounded by the requirement for costly counter-sinking of the paneledges to avoid an unsightly gap between adjacent panels. In the eventthat the panels are made of synthetic materials, such as plastic,according to current trends, counter-sinking for butt hinge installationis an impracticality and usually is avoided. In addition, theutilization of fastening screws with plastic materials is not totallysatisfactory since there is a marked tendency of the screws to loosenand back-out of the plastic after repeated operations of the doors.

As a consequence of the above and other factors currently recognized inthe industry, not the least of which is the high cost of skilled labor,the need has arisen for improved folding door hardware, principallyhinges and alignment means, which are adapted to accurate and quickinstallation both in the factory and in the field. It is to this growingneed that the present invention is addressed.

In my prior application, Ser. No. 335,231 filed Feb. 13, 1973, now US.Pat. No. 3,813,730, issued June 4, 1974, I have disclosed the featuresof an improved hinge means made of molded plastic and incorporationgnovel plug elements for mounting the hinges in the edges of a door orpanel by insertion into machined sockets bored into the door edges. Theplug elements carry metal anchoring devices for retaining the same inthe sockets, 'thereby to secure the hinges in place. While furtherreference may be had to the aforenoted prior application for amplifyingdetails of construction as set forth therein, suffice it to say that theanchoring system disclosed therein has proven to be relatively expensiveand complex as compared to the improved structure of the presentinvention.

In brief, among other features, the present invention is directed toimprovements over the hinge disclosed in my prior copending applicationSer. No. 335,23 l now US. Pat. No. 3,8l3,730, issued June 4, I974,including the provision ofa simplified anchor means of improvedretention capabilities for face or edge mounting hardware to a door orpanel, and unique detent means for holding doors in coplanar conditionover a door opening; the hardware being basically of thermoplastic orsynthetic material construction which lends itself to low cost, highproduction and is capable of accurate and positive installation withminimum time and skill.

It is a principal object of this invention to provide improved hinge andalignment hardware assemblies, particularly useful with folding doors,panels, shutters and the like and which assemblies embody novel meansfor mounting the same to either face or edge portions of the doors andpanels with which they are used.

Another important object of this invention is to provide improvedhardware assemblies as aforesaid, which are dependable in use andexhibit economies of manufacture and installation.

Another object of this invention is to provide an improved system ofunobtrusively attaching hinge and alignment assemblies to panels anddoors having machine bored mounting sockets formed in the edges or facesthereof.

A still further object of this invention is to provide improved hingeassemblies for use with lightweight doors and panels, particularly ofthe folding variety, which embody improved means for maintaining thedoors and panels in coplanar condition.

Having thus described the present invention, the above and furtherobjects, feature and advantages thereof will appear from time to time tothose of skill in this art from the following detailed description of apreferred embodiment thereof illustrated in the accompanying drawingsand setting forth the features of my present invention so as to enablethose familiar with this art to make the practice the same.

In the drawings:

FIG. 1 is a front elevational view of a folding door or panelinstallation utilizing the improved hinge and alignment hardwareassemblies of my invention;

FIG. 2 is an enlarged plan view of a hinge assembly of this inventionedge mounted on a pair of door panels, as taken from vantage line 22 ofFIG. 1;

FIG. 3 is a cross-sectional view taken substantially at line 3-3 of FIG.2 and looking in the direction of the arrows thereon;

FIg. 4 is perspective view of the hinge assembly illustrated in FIGS. 2and 3;

FIG. 5 is perspective view of another hinge assembly according to thisinvention, illustrated in edge mounted condition intermediate the upperand lower ends of a pair of folding panels or doors,

FIG. 6 is a perspective view of one hing element of the assemblyillustrated in FIG. 5;

FIG. 7 is a partial enlarged front elevational view, with parts insection, of an improved door alignment assembly mounted according tothis invention;

FIG. 8 is a cross-sectional view taken substantially from vantage line88 of FIG. 7;

FIG. 9 is an exploded perspective view showing the elements of thealignment assembly illustrated in FIGS. 7 and 8;

FIG. 10 is another perspective view of one alignment member of theassembly illustrated in FIGS. 7 and 8;

FIG. 11 is a sectional view of a modified face mounted hinge assemblyaccording to this invention; and

Flg. 12 is an elevational view of the face mounted hinge assembly shownin FIG. 11.

DESCRIPTION OF THE PREFERRED EMBODIMENT Turning now to the features ofthe particular embodiment of this invention, which is shown in theaccompanying drawings for exemplary purposes, initial attention isdirected to FIG. 1. As there shown, a structural wall or partition isprovided with a door opening 16 as for example, the entrance to acloset. A typical bi folding door installation is mounted across opening16 to close over the same and in the particular case shown comprisesfour planar door panels 17, 18, 19 and 20. The door panels 17 and 18 arehingedly interconnected as are the door panels 14 and 20 to provide atypical bi-folding door installation which, among other advantages, hasthe ability of providing substantially full access to the door opening,yet is capable of substantially closing over the same while requiringless space for swinging movements of the panels during the opening andclosing operations.

While this invention is particularly concerned with improved features ofhinge and alignment hardware useful with doors, panels, shutters,decorative screens and the like, it is expecially suited forinterconnecting adjacent panels of a bi-fold door installation.

Door opening 16 is bounded by lintil across its top, vertical jambmembers 26 and 27 along its lateral sides and a floor sill member 28across its bottom. In the particular bi-fold door installation shown, ahorizontal guide track 29 is attached to the lintil member 25 to provideguiding movements to oppositely moving panels 18 and 19 of the twointerconnected pairs thereof, as the same move back and forth acrossopening 16.

Considering the right hand pair of panels 17 and 18 initially, it willbe recognized that panel 17 is supported by pivot members 30 and 31which are axially aligned and located inwardly of one lateral edgethereof in close parallelism to jamb member 26. Pivot member 30 isusually supported in the track member 29 as shown, while the lower pivotcenter 31 is normally supported on an angle bracket 32 carried by thefloor sill 28 and the jamb member 26. The opposite lateral edge 33 ofpanel 17 is mounted in spaced parallelism to the adjacent lateral edge34 of panel 18 by improved hinge assemblies 35, 36 and 37 of thisinvention while a pivotal guide roller 38 is mounted to the upper edge39 of panel 18 adjacent the opposite lateral margin 40 thereof forengagement with the track means 29 in a conventional and known fashion.An improved alignment assembly 41 comprising a pair of alignment members42 and 43 is mounted at the lower adjacent corners of the panels 18 and19, to maintain such panels coplanar in their closed positions.

While the above description is concerned primarily with the hardwareassociated with the one pair of panels l7 and 18 in FIG. 1, it will beunderstood that the left hand pair of panels 19 and 20 of the bi-foldinstallation illustrated are likewise equipped with top and bottom pivotcenters 30, 31, top and bottom hinge assemblies and 37 and anintermediate hinge assembly 36 as well as guide roller means 38 and onemember of the alignment assembly 41. For purposes of the presentdisclosure, the description which follows will concern itself primarilywith the hinge and alignment assemblies associated with the two righthand door panels 17 and 18 to avoid unnecessary repetition.

It will be understood from the foregoing brief description that with thepanel pairs interhinged for relative swinging movement about theinterconnecting hinge assemblies 35, 36 and 37 and pivotal movementabout the pivot centers 30, 31, the same are adapted to swing about twoaxes so as to fold toward one another during opening movements.Conversely, the closing movements of the hinged panels produces agenerally coplanar closed relationship therebetween, as illustrated inFIG. 1. In order to assist in the opening and closing movements of thedoors, suitable knobs or hand grips 44 are usually provided on theexteriors of the privotally supported panels 17 and 28, generally nearthe mid-regions thereof, as shown.

As noted above, a bi-fold door installation of the type illustrated ispreferably provided with the alignment assembly 41 composed of theindividual members 42 and 43, one thereof being attached to each of theadjacent mid-panels l8 and 19. In operation the alignment assembly 41serves to align the free edges of the two panels 18 and 19 in coplanarrelationship and hold the door panels in proper position at and adjacentthe lower ends thereof in cooperation with the roller guide means 38, 38at the upper edges of such panels, to maintain a desired coplanarrelationship therebetween in the closed condition of the doorinstallation. The operating features and advantages, as well as thestructural aspects of the alignment assembly 41, will be described ingreater detail hereinafter from which the foregoing generalities ofoperation will be readily recognized.

Turning now to the particulars of the improved hinge assemblies 35 and37 of this invention, reference is made to FIGS. 2, 3 and 4 of thedrawings illustrating an upper or top hinge assembly 35. In this regardit should be appreciated and recognized that the bottom hinge assembly37 is substantially identical to the upper assembly 35 except that theindividual members or elements thereof are inverted and reversablypositioned so that a description of a top assembly will suffice forboth.

Be that as it may, hinge assembly 35 is made up of two unitary hingemembers or elements 50 and 51, each preferably molded from thermoplasticmaterial, such as Nylon, or alternatively cast or drawn from metal.

As shown, a male hinge element 50 has a generally planar body portion 52of substantially square plan profile and of rectangular cross-section.The bottom surface 53 of the body member 52 constitutes a planar guidesurface adapted to abut the adjacent end surface of the door panel onwhich it is mounted, such as end surface 39 on panel 18. Formedintegrally with body portion 52 is a depending cylindrical mounting plugportion 55 for mounting the hinge element in an accurately locatedmounting socket 56 (see FIG. 3) formed inwardly of the end surface 39 ofthe door panel. Plug portion 55 is distinguished by a generally taperedaxial opening 57 extending centrally therethrough for reception of atapered locking pin 58. The central opening 57 also openly communicateswith the exterior surface 59 of the mounting plug via a slotted aperture60 which extends radially through the main body portion 52 for the fullaxial length of the mounting plug. Because of this construction, thewalls of the body portion normally contract to close the slot 60 at itslower end. However, insertion of the locking pin 58 in opening 57radially expands the walls of the plug portion to restore itscylindrical shape and positively lock the latter in the mounting socket56.

It will further be appreciated from an examination of FIGS. 3 and 4 inparticular that the external wall 59 of the mounting plug portion isdistinguished by one or more radially projecting ribs 62 and rows oflocking barbs or teeth 63. In the normal non-expanded or unmountedcondition for the mounting plug portion, the same is somewhat tapered inexternal configuration due to the slotted opening 60 being closed at thelower end thereof as above noted. Thus theplug is readily insertableinto the cylindrical socket 56. However, after inserting the plugportion into its socket, driving the pin 58 into opening 57 causesradial expansion of its flexible wall portions to drive the teeth 63,and rib elements 62 into the side walls of the socket, preventingrotational movement of the plug portion in the socket. Also, since thetang portions of teeth 63 are reversely formed and readily penetrate andgrip the side walls of the socket 56, ready withdrawal of the mountingplug portion is prevented. In practice it has been found that theutilization of the locking pin and expandable mounting plug portionsprovides a superior system for retaining hinge assemblies in the door ina secure fashion. This is true for both wood and plastic door materi-.als.

In addition to the mounting plug portion 55, the body 52 of the malehinge element 50 is provided with a depending flange skirt 65 on onemargin thereof, preferably along its rearward margin as viewed in FIG.2. Flange skirt 65 like the body portion 52 is provided with a planarinner face 66 adapted to engage the rearward face 67 of the door 18;face 66 being formed at substantially right angles to the lower guidesurface 53 of the body portion. With proper location of the mountingsocket 56 in conjunction with the mounting plug portion 55 and theflange wall 65, the male hinge element 50 is accurately and positivelylocated over the door edge in its installed position as illustrated inFIG. 3.

It will be observed that in addition to the flange wall 65, body portion52 of the hinge element 50 is also provided with an outwardly projectinghub portion 70, formed at one end of flange 65 and located outwardly ofbody portion 52. Hub portion 70 also projects outwardly of the generalplane of the flange wall 65 and is provided with a central axial boreopening for reception of a hinge pin 71 definitive of the hinge axisbetween the two hinge elements 50 and 51 in assembly. Preferably asillustrated, the axis of the hinge pin 71 is located rearwardly of therear face 67 of the door panels 18 opposite the gap between the opposingadjacent edges 33 and 34 of the interhinged panels 17 and 18 as bestillustrated in FIG. 2. In this latter regard, it will be appreciatedthat the location of the hinge axis for the hinge elements is determinedby the positioning of the mounting socket 56 relative to the edges ofpanels 17 and 18 and to that end the formation of the mounting socketspreferably is performed with an accurate jig or boring fixture so as toadapt such formation to machine operation, according to currentlyrecognized practice.

In addition to the portions of the male hinge element 50 heretoforedescribed, it will be recognized from FIGS. 2 and 4 in particular, thatone lateral edge or margin 73 thereof which, in the mounted position forhinge assembly 35, as illustrated in FIG. 2, lies closest to door edge34 and the adjacent female hinge element 51, is configured with anoutwardly extending finger portion 75 having a hook element 76 spacedfrom a recessed margin 77 located at the corner of the body portion 52opposite the hub portion 70.'lt further will be noted that the outermargin of the finger portion is substantially coplanar with the hingeaxis defined by the pin 71, for reasons which will appear presently.

Turning now to the features of the female hinge element 51, it will berecognized from FIG. 4 that the same includes a planar body portion 80formed integrally with a depending mounting post portion 81 identical inall respects to the previously described post portion 55. As with thelatter, mounting post portion 81 is operatively arranged to receive atapered pin 58 in opening 57 for radially expanding the same inaccordance to the construction previously set forth. Like the male hingeelement, female hinge element 51 incorporates an integrally formedflange or skirt wall portion 82 along the rearward marginal edgethereof; the same being formed at right angle relationship to the planarunderface 83 of body portion 80 to fit tightly against the rear face 84of panel member 17 in operation. Further, the skirt wall portion 82extends rearwardly at its intersection with edge 85 of the body portionto terminate in a cylindrical boss or hub 86 having a central axialopening therethrough and receptive of the hinge pin 71; hub 86 beingregisteringly disposed over the hub portion 70 of the male hinge elementin assembly. In addition, the marginal edge 85 of the body isdistinguished by an outwardly projecting finger 87 having a hook element88 opposite the hub 86 and adjacent an inwardly extending recess 89provided to receive the finger portion 75 of the male hinge element whenthe same are in a closed hinge position as illustrated in FIG. 2. Itwill be recognized that the two hook elements 76 and 88 oppose oneanother and resiliently interlock in the closed position of the hingeelements; element 88 springing past the stiffer hook portion 76 duringthe opening and closing operations of. the hinge assembly. Once the hookelements are inter-engaged, as, illustrated in FIG. 2, the same act as asemi-positive holding detent means for maintaining the associated panels17 and 18, inter-connected by the hinge assemblies 35 and 37, in planarclosed condition against accidental opening. This happenstance occurs,for example, when one set of bifold panels is closed and the other setis closed suddenly to pressurize the air in the closet so that theoutward rush of air has a tendency to open the closed panels at theirhinge junctions. Heretofore separate hardware assemblies have beenemployed to prevent this accidental partial opening of the door panels.The present unique system of interlocking hinge elements is believed tobe a novel advancement in this art for overcoming this problem.

From the above description of the hinge assembly 35, it will be readilyappreciated that with the mounting plug portions inserted into theirrespective sockets in the top edges of the adjacent door panels 17 and18, the engagement of the skirt elements or portions 65 and 82 with therear faces of the two panels 17 and 18 tightly locates and maintains thehinge elements in their proper operating position so that the axis ofthe hinge pin 71 lies opposite the gap between the opposing ad jacentedges 33 and 34 of the panels. Driving the locking pins 58 into thecentral openings of the mounting plug portions radially expands thelatter within their mounting sockets, driving the tangs of toothelements 63 into the side walls of such sockets to assist in positivelyanchoring the hinge assembly in position in a most effective manner.Furthermore, it will be noted that the location of the hinge axis at pin71, rearwardly of the rear faces of panels 17 and 18 and the positioningof the skirtwalls 65 and 82 against the rear faces of such panelssubstantially hides the hinge assembly leaving only the leading edges ofthe body portions exposed to view from the door front. In effect, theexposed portions of the top hinge assembly are relatively unobtrusiveinasmuch as the same are at the upper ends of the doors and aregenerally hidden to the normal sight of the viewer.

In a similar fashion, of course, the bottom hinge assembly 37 is mountedat and between bottom end edges of the door panels 17 and 18 tocooperate with the upper hinge assembly in determining the hingingmovements of such panels about their respective hinge pins which arecoaxially aligned. It further will be undcrstood that by utilizing anaccurate jig boring setup, the location of the mounting sockets 56 inthe end edges of the doors, is such as to maintain a desirable fixedmounting position for the hinge assemblies to insure a proper, butunsightly gapping or space between adjacent opposing edges 33 and 34 ofthe two panels 17 and 18. This problem in itself has been much cause forconcern in bi-fold door assemblies in the past and of course issuccessfully confronted and solved by the hinge assembly of thisinvention.

Turning now to the features of the intermediate hinge assembly 36mounted substantially medially of the door panels for cooperation withthe top and bottom hinge assemblies 35 and 37 (see FIG. 1) attention isinitially directed .to FIGS. and 6 of the drawings illustrating thedetails and operational aspects thereof. As shown, assembly 36 comprisesa top hinge element 90 and a bottom hinge element 91, which areidentical in all respects. For purposes of the present disclosure, thedecription of the bottom hinge element 91, specifically shown inperspective in FIG. 6, will suffice for both.

Element 91 is formed, as with the hinge assemblies, of cast or drawnmetal or molded plastic, and includes a planar body portion 93substantially rectangular in configuration and of a thickness equal toor just slightly less than a desired gap or spacing between opposinglateral edges 33 and 34 of the panels 17 and 18, for example; Outwardlyof the rearward face 94 of the body portion 93 is a mounting plugportion 95, identical in all respects with the mounting plug portions 55and 81 of the hinge assembly 35 hereinabove described. That is to say,the mounting plug portion 95 is a generally cylindrical moldedprojection having an elongated axially extending opening 96 receptive ofa tapered locking pin 97 and split by an axially extending slot 98 topermit radial flexing or contracting and expanding movements of the plugportion. A plurality of barbs or teeth 99 project from the exteriorsurface of the mounting plug portion as in the previously describedconstruction. It will be noted also that the uppper edge of the bodyportion 93 extends diametrically across the cylindrical formation of themounting plug portion 95, bisecting the central opening 96 which alsopartially interrupts the body 93. The outer or left hand end of the bodyportion 93, as illustrated in FIG. 6, is formed with a cylindrical hub100 having a central bore opening 101 therethrough for receiving a hingepin 102 in its assembly with the upper hinge element (see FIG. 5).

As previously noted, the upper hinge element 90 of the intermediatehinge assembly 36 is identical to the lower hinge element 91 justdescribed, being however reversibly positioned from the latter inassembly therewith so that the hub portion a thereof is axiallysuperimposed over the hub portion 100 for reception of the hinge pin102. In assembly with the two door panels 17 and 18, two bored socketsof cylindrical formation are formed inwardly of the door edges 33 and34, the axes thereof being aligned for coaxially receiving the mountingplug portions 95 and 95a of the two hinge elements. The locking pins 97are driven into the central openings 96 to tightly lock the hingeelements in operating position so that their hinge axis, defined by pin102, is coaxially aligned with the hinge pins of the top and bottomhinge assemblies 35 and 37 rearwardly of the back faces of the twopanels 17 and 18. It further will be noted that the relatively thin bodyportions 93a and 93 of the two hinge elements 90 and 91 are disposed inthe gap or space between the opposing door edges 33 and 34, with thebody portion 93a of the upper hinge element 90 swinging registeringlyover the body portion 93 of the lower hinge element in the closedposition of the door panels.

While the edge-mounted intermediate hinge assembly 36 hereinabovedescribed is preferred in most instances because of its relativelyunobtrusive appearance when the door panels are closed, it isnevertheless quite apparent when the door panels are in their openposition inasmuch as the lateral edges 33 and 34 of the adjacent panels17 and 18 are then in full view to the onlooker.

As an alternative, a face mounted intermediate hinge assembly 106, ofFIGS. 11 and 12, may be utilized. From an examination of those'figures,it will be seen that the -modified face-mounted assembly 106 comprisesmale and female hinge elements 107 and 108, respectively. As shown bestin FIG. 12, the male element 107 has a generally planar body portion 109of substantially rectangular profile with a medially located projection110 at one end thereof and comprising a cylindrical hub for reception ofa hinge pin 111.

Spaced laterally from the hub porton 1 10 and extending'rearwardly ofthe back face 112 of body portion 109 is a mounting plug portion 113,adapted to fit into a bored socket l 14 formed inwardly of the face 67of door panel 18, for example. It will be noted that the exterior ofplug portion 113 is generally cylindrical and provided with rows ofprojecting teeth 115. A slot 116 splits the body of the plug portion andan axially extending central opening 1 17 receives a locking pin 118, asin the mounting plug portions previously described hereinabove. It is tobe noted, however, that the axially extent of the plug portion 113 issomewhat foreshortened from that described in association with the topand bottom hinge assemblies 35 and 37 and the intermediate assembly 36.Therefore, the mounting sockets 114 therefor are commensuratelyforeshortened. Be that as it may, the operation of the mounting plugportion and the locking pin 1 18 therefor is identical to that describedhereinabove.

The female hinge element 108 is formed substantially identical to thatof the male element 107 with the exception that the body portion 120thereof is formed with a pair of spaced hub portions 121 and 122 at theupper and lower corners of one marginal edge 123 thereof; the spacingbetween the portions 121 and 122 being such as to accommodate the linearextent of the hub portion 110 on the male hinge element 107. Thus, inassembly hub portion 110 of the male hinge element is interfittedbetween the separated hub portions 121 and 122 of the female hingeelement for reception of the hinge pin 111 therethrough. Again, it willbe noted that the hinge pin 111 is disposed opposite the gap betweenopposing edges 33 and 34 of the adjacent door panels 17 and 18, forexample, with such location of the hinge axis being determined by thelocation of the mounting sockets 114 which preferably are formed bymachine in a boring jig for accuracy of alignment.

It will be appreciated that the face mounted intermedate hinge assembly106 is a ready substitute for the edge-mounted intermediate hingeassembly 36 of FIG. and is the full operational equivalent thereofcomprising the same concept and mode of attaching the same to the doorpanels, via the mounting plug portions and locking pins.

As mentioned hereinbefore, in addition to the hinge assemblies of thisinvention, the same comprises an alignment assembly which is illustratedbest in FIGS. 7 through 10 of the drawings. It will be recalled that thealignment assembly 41 is typically disposed between the lower corners ofadjacent door panels of opposing pairs in a bi-fold door installation,such as panels 18 and 19 illustrated in FIG. 1. Assembly 41 serves toalign adjacently opposing panels in coplanar condition when the doorsare closed. A better understanding of the functioning and structure ofthe alignment assembly 41 will be gained by initial examination of FIGS.9 and 10 of the drawings.

As illustrated in FIG. 9, the right-hand alignment member 42 of assembly41 comprises a planar body portion 125 having a mounting plug portion126 projecting upwardly of the upper face thereof for reception in amounting socket 127 formed inwardly of the bottom edge 128 of the righthand door panel 18 in the four door panel installation illustrated inFIG. 1. The mounting portion 126 is split, has externally projectingteeth and receives a mounting or locking pin 130 through a centralaxially opening 131 therein, all in the manner of that describedpreviously in association with the hinge assemblies 35 and 36, forexample.

Projecting outwardly of the rearward margin of body portion 125 is anupwardly extending right-angularly disposed wall or flange 132 having aplanar face adapted to closely hug and fit against the rearward face ofthe door panel 18, in the same manner as the wall portions 65 and 82associated with the top and bottom hinge assemblies 35 and 37 (see FIG.8). Wall portion 132 is formed integrally with a lateral extendingcoplanar narrowed arm portion 133 which is aligned with the upper edgeof the wall portion 132 and extends a distance sufficient to bridge thegap 135 between the adjacently opposed edges 40 and 40a of the doorpanels 18 and 19 in operation (see FIG. 8). The outer end of the armportion 133 is angled rearwardly at substantially 45 to provide a guidefinger portion 136. This finger portion is adapted to resiliently engagethe rear corner edge of the left hand panel 19 or that is, theintersection of face 137 and the edge 40a thereof to guide the panel 19forwardly during its closing movements so as to engage the rearward face137 thereof with the inside face 138 of the arm portion 133 when thedoors are closed. Due to the fact that the material from which the guideelement 42 is fashioned preferably is a thermoplastic material, such asNylon, it has relatively good flexibility. As a consequence, arm 133 isslightly flexed rearwardly when engaged by the face 137 of panel 19,closely hugging the same and keeping panel 19 aligned nicely with therear face of panel 18. slightly flexed rearwardly when engaged From abrief examination of FIG. 10, it will be appreciated that the left handguide member 43 of the assembly 41 is substantially identical to theright hand guide element 42 just described, with the exception that theguiding arm portion 140 thereof, and consequently the projectingangulated finger portion 141 attached thereto, projects outwardly fromnear the bottom marginal corner of its flange wall 142 substantiallywhere the latter intersects of the main body 143 of member 43. With thisarrangement it clears the arm and finger portions 133 and 136 of theright hand guide member 42 when the two doors 18 and 19 are moved towardtheir closed positions. (See FIGS. '7 and 8).

As with the right hand guide member 42, the left hand member 43 ofassembly 41 includes an upwardly projecting split mounting plug portion145 to enter a bored mounting socket 146 formed inwardly of the bottomedge 147 of the left hand door panel 19 for mounting member 43 inoperating position. A locking pin 130, as utilized with the right bandmember 42, is employed to securely lock the member 43 to the door panel19 by radially expanding the split mounting plug portion 45 inside ofsocket 146.

From the foregoing description, it is believed that those familiar withthe art will readily recognize and appreciate the novel departure of thepresent invention over the prior art and particularly will recognize andappreciate the advantages of the improved mounting system employedwhereby the hardware assemblies are readily attachable to the edges orfaces of door panels and securely locked in position in mounting socketstherefor. It further is to be recognized that while the presentinvention has been hereinabove described in association with a preferredembodiment illustrated in the accompanying drawings, such embodiment isreadily amenable to change and alteration without departing from thespirit and scope of the disclosed invention, as set out in the followingclaims:

I claim:

1. For use in guiding and hingedly interconnecting adjacent panels infolding door installation and the like, a hardware assembly comprising:a pair of molded members adapted to be cooperatingly mounted on adjacentpanels, each said member having a body portion formed with a planarguide surface engagable with a planar surface of a said panel on whichits associated said member is mounted, a genrally culindrical radiallyflexible plug portion formed integrally with said body portion andextending perpendicularly outward of said guide surface thereon, saidplug portion having externally projecting barbs and a central axialopening extending therethrough and said body portion; said plug portionbeing insertable into a cylindrical mounting socket formed inwardly ofsaid planar surface of said panel, and tapered pin means insertablethrough said body portion into said axial opening for radially expandingsaid plug portion in said socket thereby to securely set said barbs andanchor its said associated member to said panel.

2. The combination of claim 1 wherein said members are hinge elementsformed integrally with interfittable hub portions, and binge pin meanscoaxially interconnecting said hub portions, and defining an axis ofhinging movement therebetween.

3. The combination of claim 1, and a planar skirt wall formed integrallywith said body portion projecting perpendicularly outwardly from onemargin thereof, parallel to the axis of said plug portion, said skirtwall having a planar guide face for abutting a second surface of a paneldisposed perpendicularly to the said planar surface thereon whereby toalign said member on said panel.

4. The combination of claim 3, and a hub portion formed along one marginof said skirt wall, the said hub portions of adjacent membersinterfitting in operation and having coaxial openings therethrough, andhinge pin means mounted in said coaxial openings and definitive of anaxis of hinging movement for said members, which said axis is locatedoutwardly of corresponding said second surfaces of adjacent panels inthe mounted position of said assembly thereon.

5. The combination of claim 3, and an elongated guide portion extendingangularly outwardly of the said skirt wall, said guide portions ofadjacent members of the assembly projecting toward one another andoverlapping in the mounted position of the members on adjacent panels,with each said guide portion resiliently engaging the said secondsurface of an adjacent said panel as the panels move toward coplanarpositions thereby to align and hold adjacent said panels in coplanarposition.

6. The combination of claim 2 in which the said sockets for said memberof the assembly are formed inwardly of corresponding edge surfaces ofadjacent panels in selected locations positioning said axis of movementtherefor opposite the space between said adjacent panels, and detentmeans comprising interfitting resilient portions formed integrally withthe body portions of said members and along opposing margins thereof foroperably retaining said opposing margins adjacently parallel when thesaid panels attached thereto are in coplanar positions.

7. The combination of claim 1 wherein said pair of members comprisehinge elements, and said mounting socket associated with each thereof isformed in an edge surface of one of said adjacent panels associatedtherewith, and detent means adapted to resiliently interlock saidmembers comprising cooperating projections inteferingly formed onopposed margins of the body portions thereof and engageable when thepanels attached thereto are coplanar.

8. The combination of claim 2 wherein the socket for each member of saidpair is formed inwardly of an end edge surface of a said panel and islocated so as to dispose said hub portions opposite the space betweenopposed lateral edges of said adjacent panels.

9. The combination of claim 2 wherein the sockets for said pair ofmembers are coaxially aligned in opposite lateral edges of adjacent doorpanels, and the said plug portion of each body portion extends beyondone marginal edge thereof, whereby said body portions are positioned incoplanar adjacency between said plug portions in the coplanar closedposition of said panels.

10. The combination of claim 2 wherein the sockets associated with eachpair of hinge elements are formed inwardly of corresponding planar facesurfaces of said adjacent panels and the axis of hinging movementtherebetween lies opposite the gap between opposing marginal side edgesof said panels.

11. The combination of claim 1 wherein said plug portions are generallycylindrical and are split longitudinally to permit radial expansion andcontraction thereof.

12. For use in hingedly interconnecting adjacent panels in a foldingdoor installation and the like, a hardware assembly comprising: a pairof molded hinge members cooperatingly mounted on adjacent panels formovement about a hinge axis therebetween, each said hinge member havinga body portion formed with a planar guide surface engageable with aplanar surface of one of said panels, a radially expandable andcontractable plug portion formed integrally with said body portion andextending perpendicularly outward of said guide surface thereon, saidplug portion being axially insertable when in a radially contractedcondition into a cylindrical mounting socket therefor formed inwardly ofsaid planar surface on a said panel, means for radially expanding saidplug portion to activate means for resisting removal thereof from a saidsocket thereby to secure its associated said member to said panel, anddetent means having cooperating interlocking portions on each of saidmembers and operable to restrain movement thereof about said axis.

13. The combination of claim 12 wherein said means for resisting removalof said plug portion comprises tooth projections on the exterior wall ofsaid plug portion having integral barbs projecting toward the said guidesurface to grip the walls of a socket into which a plug portion isinserted.

1. For use in guiding and hingedly interconnecting adjacent panels infolding door installation and the like, a hardware assembly comprising:a pair of molded members adapted to be cooperatingly mounted on adjacentpanels, each said member having a body portion formed with a planarguide surface engagable with a planar surface of a said panel on whichits associated said member is mounted, a genrally culindrical radiallyflexible plug portion formed integrally with said body portion andextending perpendicularly outward of said guide surface thereon, saidplug portion having externally projecting barbs and a central axialopening extending therethrough and said body portion; said plug portionbeing insertable into a cylindrical mounting socket formed inwardly ofsaid planar surface of said panel, and tapered pin means insertablethrough said body portion into said axial opening for radially expandingsaid plug portion in said socket thereby to securely set said barbs andanchor its said associated member to said panel.
 2. The combination ofclaim 1 wherein said members are hinge elements formed integrally withinterfittable hub portions, and hinge pin means coaxiallyinterconnecting said hub portions, and deFining an axis of hingingmovement therebetween.
 3. The combination of claim 1, and a planar skirtwall formed integrally with said body portion projecting perpendicularlyoutwardly from one margin thereof, parallel to the axis of said plugportion, said skirt wall having a planar guide face for abutting asecond surface of a panel disposed perpendicularly to the said planarsurface thereon whereby to align said member on said panel.
 4. Thecombination of claim 3, and a hub portion formed along one margin ofsaid skirt wall, the said hub portions of adjacent members interfittingin operation and having coaxial openings therethrough, and hinge pinmeans mounted in said coaxial openings and definitive of an axis ofhinging movement for said members, which said axis is located outwardlyof corresponding said second surfaces of adjacent panels in the mountedposition of said assembly thereon.
 5. The combination of claim 3, and anelongated guide portion extending angularly outwardly of the said skirtwall, said guide portions of adjacent members of the assembly projectingtoward one another and overlapping in the mounted position of themembers on adjacent panels, with each said guide portion resilientlyengaging the said second surface of an adjacent said panel as the panelsmove toward coplanar positions thereby to align and hold adjacent saidpanels in coplanar position.
 6. The combination of claim 2 in which thesaid sockets for said member of the assembly are formed inwardly ofcorresponding edge surfaces of adjacent panels in selected locationspositioning said axis of movement therefor opposite the space betweensaid adjacent panels, and detent means comprising interfitting resilientportions formed integrally with the body portions of said members andalong opposing margins thereof for operably retaining said opposingmargins adjacently parallel when the said panels attached thereto are incoplanar positions.
 7. The combination of claim 1 wherein said pair ofmembers comprise hinge elements, and said mounting socket associatedwith each thereof is formed in an edge surface of one of said adjacentpanels associated therewith, and detent means adapted to resilientlyinterlock said members comprising cooperating projections inteferinglyformed on opposed margins of the body portions thereof and engageablewhen the panels attached thereto are coplanar.
 8. The combination ofclaim 2 wherein the socket for each member of said pair is formedinwardly of an end edge surface of a said panel and is located so as todispose said hub portions opposite the space between opposed lateraledges of said adjacent panels.
 9. The combination of claim 2 wherein thesockets for said pair of members are coaxially aligned in oppositelateral edges of adjacent door panels, and the said plug portion of eachbody portion extends beyond one marginal edge thereof, whereby said bodyportions are positioned in coplanar adjacency between said plug portionsin the coplanar closed position of said panels.
 10. The combination ofclaim 2 wherein the sockets associated with each pair of hinge elementsare formed inwardly of corresponding planar face surfaces of saidadjacent panels and the axis of hinging movement therebetween liesopposite the gap between opposing marginal side edges of said panels.11. The combination of claim 1 wherein said plug portions are generallycylindrical and are split longitudinally to permit radial expansion andcontraction thereof.
 12. For use in hingedly interconnecting adjacentpanels in a folding door installation and the like, a hardware assemblycomprising: a pair of molded hinge members cooperatingly mounted onadjacent panels for movement about a hinge axis therebetween, each saidhinge member having a body portion formed with a planar guide surfaceengageable with a planar surface of one of said panels, a radiallyexpandable and contractable plug portion formed integrally with saidbody portion and extending perpendicularly outward Of said guide surfacethereon, said plug portion being axially insertable when in a radiallycontracted condition into a cylindrical mounting socket therefor formedinwardly of said planar surface on a said panel, means for radiallyexpanding said plug portion to activate means for resisting removalthereof from a said socket thereby to secure its associated said memberto said panel, and detent means having cooperating interlocking portionson each of said members and operable to restrain movement thereof aboutsaid axis.
 13. The combination of claim 12 wherein said means forresisting removal of said plug portion comprises tooth projections onthe exterior wall of said plug portion having integral barbs projectingtoward the said guide surface to grip the walls of a socket into which aplug portion is inserted.